WO2022016083A1

WO2022016083A1 - Panel and method of forming same

Info

Publication number: WO2022016083A1
Application number: PCT/US2021/042025
Authority: WO
Inventors: George R. BREIWA III; Nicholas STUHR
Original assignee: Breiwa Iii George R; Stuhr Nicholas
Priority date: 2020-07-16
Filing date: 2021-07-16
Publication date: 2022-01-20

Abstract

A panel is disclosed. The panel comprises a single, monolithic planar substrate. A coating is provided on the substrate, and an image is transferred thereon. The panel is formable into a non-planar structure. In one example the non-planar structure is an artwork. In another example the non-planar structure is a table tent. A mailer is also disclosed. Methods of forming the panel and the mailer are also provided.

Description

PANEL AND METHOD OF FORMING SAME

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims priority to United States Provisional Application, Serial

No. 63/052,804, filed July 16, 2020, entitled Art Panel and Method of Forming Same; this application also claims priority to United States Provisional Application, Serial No. 63/140,113, filed January 21, 2021, entitled Mailer and Method of Forming Same; and this application further claims priority to United States Provisional Application, Serial No. 63/165,407, filed March 24, 2021, entitled Mailer and Method of Forming Same, the entire contents of each of which is hereby incorporated by reference herein in their entirety.

BACKGROUND

[0002] The present disclosure relates to panels. More specifically, the present disclosure relates to panels having images and/or information thereon and methods of forming same. [0003] Printing art and information on a substrate is known. Existing prints are typically made on canvas. These prints are often lower resolution. Such prints are also not eco friendly and not easy to clean. Prints on canvas and other common media are also negatively impacted by humidity. Canvas also suffers from a lack of dimensional stability, as a result additional structure must be added to support the print in a fixed manner. Consequently, these prints are not monolithic in nature. In addition, many existing panels with images thereon are limited in shape and surface texture.

[0004] Many printed or colored panels today have dyes or images applied at a topical level. This presents challenges when printing or applying an image to a substrate other than canvas, such as a metal substrate. Additionally, these types of prints can crack, fade and/or peel from the substrate under normal conditions. Furthermore, when an image is applied to a metal surface, if the metal panel or substrate is bent to a degree in excess of ninety⁷ (90) degrees, the bond between the panel and the applied image often breaks. [0005] Direct mail and flyers are also well known. Mailers and flyers are typically constructed of paper, and occasionally plastic, having an image printed thereon. Due to the ubiquitous amount of direct mail distributed and commonality, many such pieces end up in the recycling or trash. In addition, the paper substrate is generally weak, easy⁷ to rip and difficult to clean. [0006] Accordingly, a need exists for a multi-use / multi-functional panel that can be monolithically formed with vibrant images and information.

SUMMARY

[0007] A panel is disclosed. The panel comprises a single, monolithic planar substrate.

A coating is provided on the substrate, and an image is transferred thereon. The panel is formable into a non-planar structure. In one example the non-planar structure is an artwork. In another example the non-planar structure is a table tent.

[0008] An additional panel is also disclosed. This panel comprises a monolithic metal sheet having an image transferred thereon. The image comprises postal information and a graphic or other information.

[0009] A method of forming a panel is further disclosed. The method includes the steps of: creating a planar sheet in a non-rectanguiar form having one or more fold lines; providing a coating on the planar sheet; and transferring an image to the planar sheet. [0010] An art panel and a method of forming same are disclosed. The art panel comprises a single, monolithic non-planar component having an image thereon. The art panel is formed by a method that comprises punching a planar sheet or substrate to form a non-rectanguiar sheet having one or more fold lines, transferring an image to the planar sheet or substrate, and folding the panel along the fold line to form the final non-planar artwork.

[0011] A table tent and method of forming same are also disclosed. The table tent comprises a single, monolithic non-planar component having an image thereon. The table tent is formed by a method that comprises punching a planar sheet or substrate to form a sheet having one or more fold lines, transferring an image to the planar sheet or substrate, and folding the panel along the fold line to form the final non-planar table tent.

[0012] A mailer and a method of forming same are also disclosed. The mailer comprises a single, monolithic component having an image thereon suitable for delivery through the mail without envelope. The mailer is formed by a method that comprises transferring an image to a planar sheet or substrate, cutting the planar sheet or substate to a particular dimension and/or shape, and reducing or smoothing the edges to form the final mailer. [0013] These and other features and advantages of devices, systems, and methods are described in, or are apparent from, the following detailed descriptions and drawings of various examples of embodiments. BRIEF DESCRIPTION OF DRAWINGS

[0014] Various examples of embodiments of the systems, devices, and methods will be described in detail, with reference to the following figures, wherein:

[0015] FIG. 1 is a front perspective view of an art panel according to one or more examples of embodiments.

[0016] FIG. 2 is a rear perspective view⁷ of the art panel of FIG. 1.

[0017] FIG. 3 is a side elevation view' of the art panel of FIG. 1.

[0018] FIG. 4 is a rear elevation view of the art panel of FIG. I .

[0019] FIG. 5 is a cross-section view of the art panel of FIG. 1, taken along line 5-5 of FIG. 4.

[0020] FIG. 6 is a detail view' “6” of a cut out shown in the art panel illustrated in FIG. 4.

[0021] FIG. 7 is a rear elevation view of the art panel of FIGS. 1-5, showing the panel or substrate which has been cut, stamped or punched, prior to folding and formation of the non-planar panel structure.

[0022] FIG. 8 is a plan view of a first side or surface of a table tent according to one or more examples of embodiments.

[0023] FIG. 9 is a plan view' of a second side or surface of the table tent of FIG. 8.

[0024] FIG. 10 is an elevation view of an edge or side surface of the table tent of FIG. 8, showing the table tent folded or bent along a fold line.

[0025] FIG. 11 is an elevation view⁷ of the folded or bent table tent shown in FIG. 10, showing the table tent in a display orientation.

[0026] FIG. 12 is an elevation view⁷ of the folded or bent table tent shown in FIG. 10, showing the table tent in an additional display orientation.

[0027] FIG. 13 is an elevation view of a first side or surface of a mailer according to one or more examples of embodiments.

[0028] FIG. 14 is an elevation view⁷ of a second side or surface of the mailer of FIG. 13. [0029] FIG. 15 is an elevation view⁷ of a first edge or side surface of the mailer of FIG.

13.

[0030] FIG. 16 is an elevation view of a second edge or side surface of the mailer of FIG. 13.

[0031] It should be understood that the drawings are not necessarily to scale. In certain instances, details that are not necessary to the understanding of the invention or render other details difficult to perceive may have been omitted. For ease of understanding and simplicity, common numbering of elements within the numerous illustrations is utilized when the element is the same in different Figures. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.

DETAILED DESCRIPTION

[0032] Referring to the Figures, a panel 102 having an image 104 and a process of forming same are disclosed.

[0033] The panel 102 is formed of a single, monolithic component. The panel 102 may be colorized. Examples of various embodiments are shown in FIGS. 1-16. More specifically, as shown, the panel 102 comprises a monolithic, planar sheet 106 having one or more images 104 or pieces of information thereon. Generally, the panel 102 may have the property of formability into a non-planar structure. The panel 102 may also have a surface treatment or modification 108, such as an etching, engraving, perforation, and/or the like. The panel 102 may also have a unique shape.

[0034] in one or more examples of embodiments, the panel 102 comprises an image 104 (e.g., a graphic and/or artwork and/or information) provided on a surface or first surface 110 of a planar sheet 106 or substrate. This image 104 may extend the entire dimension of the planar sheet 106. Consequently, when the planar sheet 106 is formed into the desired final form of the panel 102 in certain examples of embodiments, the image 104 extends in a configuration matching the multi-dimensional shape of the panel 102 in its final form. However, it is contemplated that the image 104 may extend less than the entire dimension of the planar sheet 106 in certain examples of embodiments. Likewise, as will be discussed below, in one or more examples of embodiments, an image 104 may be provided on more than one surface of the planar sheet 106, e.g., first and second or opposing first and second surfaces 110, 112 of the planar sheet 106.

[0035] The planar sheet 106 or substrate described herein may be formed of a suitable material for achieving the desired result and suitable for the novel process described herein below. Generally, in various embodiments the substrate 106 may comprise a material having a sublimation dye transfer compatible property. However, the substrate 106 may also, or alternatively, accept direct transfer, such as but not limited to laser treatment, etching, printing, scratching, and the like, as well as combinations thereof. In one or more examples of embodiments, the planar sheet 106 or substrate may comprise a metal sheet, and in one example a thin metal sheet (see, e.g., FIGS. 15-16 which illustrate end views showing the edges 114, 116 and an example thickness of the sheet 106). In one or more examples of embodiments, the planar sheet 106 or substrate is constructed of a material suitable to receive an epoxy, examples of which include but are not limited to aluminum, carbon steel, stainless steel, and combinations thereof. In one example, the substrate is aluminum. In an alternative example of embodiments, the planar sheet 106 or substrate may be constructed of plastic. While metal and plastic are described herein for purposes of example, one of skill in the art will appreciate that alternative materials may be substituted in place thereof. For example, certain other metals or rigid materials to which an image 104 may be applied may be suitable for use as described herein.

[0036] The image 104 provided on the planar sheet 106 may comprise a sublimated dye or ink infused into (or applied to) the substrate or planar sheet 106. The image 104 may be any form of graphic, artwork, information, or other content suitable for the purposes provided.

[0037] In this regard the planar sheet 106 may be provided with a coating and “colorized.” Note: colorized may include one color such as black, as well as a fully multi-color image. Accordingly, the coating may be generally designed to accept sublimated dyes. Suitable examples may include, epoxy, acrylic, polyester, and the like. In one example of embodiments, a polymer-based coating is provided. In an alternative example of embodiments, a pow-dercoating may be provided. For example, a solvent-free powdercoating may be used. Other materials that may accept sublimation transfer may also be used.

[0038] In an alternative embodiment, the image 104 provided on the planar sheet 106 may comprise a direct transfer. Examples of such a direct transfer image 104 include an image 104 applied by laser, engraving, etching, and the like.

[0039] Accordingly, the panel 102 may generally comprise a planar sheet 106 or substrate, a coating 118, and an image 104.

[0040] The panel 102 may be formed in a variety of shapes as further illustrated in the examples set forth hereinbelow. Likewise, the panel 102 may have a surface treatment or modification 108 (e.g., perforation, etching, roughening, or other modification). In one or more examples, one or more relief cuts 120 and/or perforations 122 may also be provided on or in the panel 102. One or more apertures 124 may likewise be provided in the panel 102. It is also contemplated that one or devices (not shown) may be secured to the panel 102.

[0041] The panel 102 described herein is formed by a unique process. The process according to one example generally involves transferring an image 104 to the planar sheet 106 or substrate by a sublimation process, optionally cutting the substate to a particular dimension and/or shape, and optionally reducing or smoothing the edges to form the final panel 102.

[0042] More specifically, in the method of forming a panel 102 according to one or more examples of embodiments described herein, a planar sheet 106 or substrate is provided. An image 104 may be provided in digital form to a computer system or processor. The computer system processor then executes instructions for an apparatus which transfers the image 104 to the planar sheet 106 or substrate. The image 104 may be transferred or applied to the planar sheet 106 by sublimation transfer. That is, an image 104 is placed on the planar sheet 106 by a process in which the image 104 is moved from a solid-to-gas transition (sublimation) followed by a gas-to solid transition (deposition). In this process, sublimation dyes or inks may be transferred to the coating 118, or alternatively to sheets of “transfer” paper or polymer sheet, via liquid gel ink or dye through a print head or applicator. The ink or dye is deposited on the coating or on these high-release transfer papers. After the digital image 104 is printed onto the coating 118 or one or more transfer sheets, a heat press is used with the substrate 106. More specifically, to transfer the image 104 to the substrate 106, a heat press process is used that is a combination of time, temperature and pressure. The heat press applies this combination, w'hich can change depending on the substrate 106, to “transfer” the dyes or inks at the molecular level into the substrate or planar sheet 106. The result of this process is a permanent, high resolution, and optionally full color, image 104 on the substrate or planar sheet 106. Because the dyes or inks are infused into the substrate or planar sheet 106 at the molecular level, rather than applied at a topical level, the prints are unlikely to crack, fade or peel from the substrate 106 under normal conditions. Note, the order and number of steps may vary from the example(s) provided herein. Likewise, additional steps may be added. In one or more alternative examples of embodiments, the image may be a vector image, or a combination of a raster image and vector image. The appl ication of the vector image to the substrate with a coating provides an interactive surface for a user. The panel described herein is easily cleanable and sanitized. Moreover, the substrate is non- oxidizing. Therefore, a “coloring book,” a checklist, a “whiteboard,” and the like could be created for the user by using a vector image.

[0043] In an alternative example, the image 104 may be transferred or applied to the planar sheet 106 by direct application. That is, an image 104 may be applied to the planar sheet 106 by removal of material from the surface 110 of the planar sheet 106. One example of a direct application process involves the use of a laser, although additional examples include but are not limited to engraving and etching. To this end, in one or more al ternative examples of embodiments, the image 104 may be applied to the surface 110 of the planar sheet 106 using a laser.

[0044] It is understood that while the foregoing provides an alternative example of application of an image 104, these surface modifications 108 may be applied to any panel 102 or planar sheet 106. Likewise, the surface modifications 108 described herein may be applied prior to sublimation or may be a post-processing method. In one or more examples of embodiments, the panel 102 may be cut or surface treatment 108 applied by a laser, a water jet, a plasma cutting machine, mill, lathe, grinder, and the like. One or more ridges, arcs, chamfers, bevels, perforations, etc. may also be provided on the panel 102. For example, the panel 102 may be laser perforated or texturized in one or more locations or across a portion or an entire surface 110 or 112. Likewise, the panel 102 may be embossed, debossed, knurled, or the like. In this regard, any means of modification of the texture may be used to generate differences in tactile feel of the panel 102.

[0045] The image 104 may be applied to one side or surface 110 of the planar sheet 106, or may be applied to more than one side or surface 110, 112 of the planar sheet 106 using the foregoing methods or a combination thereof. The image 104 on multiple surfaces may be applied simultaneously or at separate times.

[0046] Either before or after the application of the image 104 the planar sheet 106 may be stamped or punched or cut to form a shape of the panel 102, e.g., a non-re ctangular shape is shown in FIGS. 7-9, 13-14. Various shapes, geometries, and surface textures are contemplated and one of skill in the art will appreciate that a variety of cuts, recesses, apertures, and even fold lines may be applied to allow the planar sheet 106 to be formed into a preferred shape, both planar and non-planar as well as both rectangular / polygonal or non-rectangular / non-polygonal. In one or more examples of embodiments, the panel 102 may comprise non-linear, non-rectangular geometry. Likewise, while the panel 102 is described herein as a planar sheet 106 it is contemplated that the mailer may have a three-dimensional configuration or be non-planar.

[0047] The use of “soft” means of forming such as but not limited to hydroforming and a bladder press are also capable of creating non-planar geometries subsequent to application of the image. The image may be pre-distorted utilizing software in anticipation of where there may be stretching and or compression due to the forming process. [0048] In one or more examples of embodiments, the edges and corners of the panel 102 may be knocked down or smoothed to reduce sharpness and burs. A variety of means are known in the art to accomplish this task, including for example, manual, thermal or electromechanical debarring, vibratory finishing, sanding, coining, and the like.

[0049] As indicated, the methods described herein may be implemented in or by software. For example, the image 104 or information may be delivered to the sublimation transfer device by software instructions. To this end, aspects of the method described herein can be implemented on software running on a computer system. The system or method herein, therefore, may be operated by computer-executable instructions, such as but not limited to program modules, executable on a computer. Examples of program modules include, but are not limited to, routines, programs, objects, components, data structures and the like which perform particular tasks or implement particular instructions. The software system may also be operable for supporting the transfer of information within a network.

[0050] The computer system may be or include a processor. The computers for use with the methods and various components described herein may be programmable computers which may be special purpose computers or general purpose computers that execute the system according to the relevant instructions. The computer system can be an embedded system, a personal computer, notebook computer, tablet computer, server computer, mainframe, networked computer, handheld computer, personal digital assistant, workstation, and the like. Other computer system configurations may also be acceptable including, cell phones, mobile devices, multiprocessor systems, microprocessor-based or programmable electronics, network PC’s, minicomputers, and the like. Preferably, the computing system chosen includes a processor suitable in size to efficiently operate one or more of the various systems or functions.

[0051] The system or portions thereof may also be linked to a distributed computing environment, where tasks are performed by remote processing devices that are linked through a communications network. To this end, the system may be configured or linked to multiple computers in a network, including, but not limited to a local area network, a wide area network, a wireless network, and the Internet. Therefore, information and data may be transferred within the network or system by wireless means, by hardwire connection or combinations thereof.

[0052] The computer can also include a display, provision for data input and output, etc. Furthermore, the computer or computers may be operatively or functionally connected to one or more mass storage devices, such as, but not limited to a database. The memory storage can be volatile or non-volatile and can include removable storage media. The system may also include computer-readable media which may include any computer readable media or medium that may be used to carry or store desired program code that may be accessed by a computer. The computer readable medium can also be distributed over a network coupled computer system so that the computer readable code is stored and executed in a distributed fashion.

[0053] These devices include a graphical user interface (GUI) or a communication means by which commands may be entered and content may be displayed or communicated.

For example, the computer may include a user interface that allows navigation of objects. The computer may implement or include an application that enables a user to display and interact with text, images, videos, data, and other information and content.

EXAMPLES

[0054] One or more specific examples of embodiments will now be described in reference to the Figures. While specific examples are provided, variations thereon and alternatives may be provided without departing from the overall scope of the present invention.

EXAMPLE 1

[0055] One specific example of a panel 102 as described herein is shown in FIGS. 1-7. Referring to these Figures, a non-planar art panel 102 or artwork formed of a single, monolithic component is disclosed. One or more examples of such an art panel 102 are shown in FIGS. 1-2. As can be seen, the panel 102 comprises a primary visible surface 110 and a plurality of folded edges 126, 128. Each folded edge 126 may also comprise a portion of the visible art surface 110, and to this end may be a secondary visible art surface. A tertiary visible (or non-visible) art surface may also be provided on edge 128. It is noted that primary, secondary', and tertiary are used only for purposes of description of the illustrated example and do not reflect the importance or any particular order of the respective surfaces. While the folded edges 126, 128 are illustrated in FIGS. 1-7 as narrow edges having two ninety-degree bends, one of skill in the art will appreciate that any number of folds (including the lack thereof) and edge dimensions may be suitable for purposes of the non-planar art panel 102. Generally', the art panel 102 is formed as a flat planar sheet 106 or two-dimensional sheet and mechanically formed into its final three- dimensional form, through the use of a double bend. As can be seen by reference to FIGS. 3 and 5, the art panel 102 in its final form is a non-planar three-dimensional panel structure.

[0056] Referring to FIGS. 2, 4, and FIG. ,5 the art panel 102 is composed of one or more folded edges 126, 128 which provide the non-planar structure described. In order to form the structure illustrated in FIGS. 1-5, various relief points 120, perforations, cutouts, fold lines, and/or score marks 122 may be provided on the planar sheet 106. One or more examples are shown in FIG. 7. As can be seen in FIG. 7, which illustrates a rear view of the art panel 102, the panel 102 or substrate 106 has been notched or cut forming relief points 120 in the corners to form a non-rectangular panel 102. The panel 102 or planar sheet 106 or substrate has also been stamped or scored or punched to provide one or more fold lines 122 which will allow the panel 102 to be folded or otherwise bent or curved into a desired final shape. As can be seen in FIG. 6, additional features can be added to the panel 102 in the form of cut-outs and the like for the intended purposes of the desired final shape. For example, as shown in FIG. 6, a cutout or aperture 124 is provided which forms a receptor for a wall hanger or fastener. While specific examples of shapes, cutouts, and score lines are illustrated herein, one of skill in the art will appreciate that these are provided for example only and variations thereon may be endless to achieve a desired final form. For instance, coupling geometry, such as but not limited to a tab, or a tongue and groove, may be added to the panel 102, such as may be used to join one or more portions of the panel 102 together after bending, or to join multiple panels.

[0057] On a surface 110 of the planar sheet 106, an image 104 or graphic or artwork is provided. In one example, the image 104 may be placed on the surface 110 opposite the score or fold lines 122. However, an image 104 may be placed on the same surface of the score or fold lines 122 or on both described surfaces. This image 104 may extend the entire dimension of the planar sheet 106. Consequently, when the planar sheet 106 is formed into the desired final form, the image 104 extends in a non-planar configuration matching the shape of the non-planar panel 102 in its final form. However, it is contemplated that the image 104 may extend less than the entire dimension of the planar sheet 106 in certain examples of embodiments. Likewise, wdrile a three-dimensional art panel 102 is shown, the art panel 102 may alternatively be a flat planar sheet 106 absent the plurality of folded edges. Alternatively, the art panel 102 may have one folded edge 126, or more than one folded edge. Numerous variations may be made without departing from the overall scope of the present invention. [0058] The art panel 102 described herein is formed by generally stamping a foldable shape into a substrate or planar sheet 106, such as a metal sheet. An image 104 is placed on the substrate or planar sheet 106 by the methods described herein. The edges 126, 128 of the sheet 106 are then folded into a non-planar shape. That is, the non-rectangular shape is folded or formed into the end product which is, in one or more examples of embodiments, a non-planar or three-dimensional artwork. Various cut-outs 120 and/or fold lines or perforations 122 placed on the non-rectangular shape during the stamping or punching process allow it to be folded into a desired non-planar end product (FIG. 7).

That is, the planar sheet 106 is stamped or punched to form a non-rectangular shape for after image application formation into the final form of an artwork panel 102. Various geometries are contemplated and one of skill in the art will appreciate that a variety of cuts, recesses, apertures, and fold lines may be applied to allow the planar sheet 106 to be formed into a non-planar object or artwork after application of the image 104.

[0059] To amplify the utility of the product, flat panels can be printed on both sides of the substrate 106 so that the user may flip the art around at their discretion.

[0060] Unlike existing products, the disclosed art panel 102 can be made in a variety of shapes. Moreover, because of the sublimation process the art panel 102 may be formed to be smooth, having no raised or textured surfaces; or alternatively, may be textured as desired. Furthermore, unlike traditional art applications to a metal surface the metal panel 102 or substrate 106 can be bent to a degree in excess of ninety (90) degrees without breaking the bond between the panel 102 and the applied image 104.

EXAMPLE 2

[0061] An alternative example of a panel 102 as described herein is shown in FIGS. 8-12. Referring to these Figures, a table tent, namely a non-planar panel 102 formed of a single, monolithic component is disclosed. One or more examples of such a table tent are shown in FIGS. 10-12. As can be seen, the panel 102 comprises a primary visible surface 110 and a folded edge 126. Each folded edge 126 may also comprise a portion of the visible surface 110, and to this end may be a secondary' image surface - visible or non- visible depending on the orientation of the table tent. It is noted that primary and secondary are used only for purposes of description of the illustrated example and do not reflect the importance or any particular order of the respective surfaces. While the folded edge 126 illustrated in FIGS. 10-12 is illustrated as a single fold with an angle less than ninety (90) degrees, one of skill in the art will appreciate that any number of folds and edge dimensions may be suitable for purposes of the non-planar panel 102. Generally, in reference to FIGS. 8-9, the art panel 102 is formed as a flat planar sheet 106 or two- dimensional sheet and mechanically formed into its final three-dimensional form using a bend. As can be seen by reference to FIG. 10, the table tent or panel 102 in its final form is non-planar and may comprise a three-dimensional panel structure.

[0062] Referring to FIGS. 10-12, the table tent is composed of one or more folded edges 126 which provide the non-planar structure described and support the table tent 102 in one or more orientations. To form the structure illustrated in FIGS. 10-12, various relief points, perforations, cutouts, fold lines, and/or score marks may be provided on the planar sheet 106. One or more examples are shown in FIGS. 8-9. As can be seen in FIG. 9, which illustrates a rear view of the table tent 102 prior to folding, the panel 102 or planar sheet 106 or substrate 106 has been stamped or scored or punched to provide one or more fold lines 122 which will allow the panel 102 to be folded or otherwise bent or curved into a desired final shape. Additional features can be added to the panel 102 in the form of cut-outs and the like for the intended purposes of the desired final shape. One of skill in the art will appreciate that the examples discussed herein are provided for purposes of example only and variations thereon may^r be endless to achieve a desired final form. For instance, coupling geometry', such as but not limited to a tab, or a tongue and groove, may be added to the panel 102, such as may be used to join one or more portions of the panel 102 together after bending, or to join multiple panels.

[0063] On a surface 110 of the planar sheet 106, an image 104 or graphic or artwork is provided. In one example, the image 104 may be placed on the surface 110 opposite the score or fold lines 122. However, an image 104 may be placed on the same surface of the score or fold lines 122 or on both described surfaces. This image 104 may extend the entire dimension of the planar sheet 106. Consequently, when the planar sheet 106 is formed into the desired final form, the image 104 extends in a non-planar configuration matching the shape of the non-planar panel 102 in its final form. However, it is contemplated that the image 104 may extend less than the entire dimension of the planar sheet 106 in certain examples of embodiments. The table tent 102 may^r have one folded edge, or more than one folded edge. While a three-dimensional table tent is shown, the table may alternatively be a flat planar sheet 106 absent the folded edge. Numerous variations may be made without departing from the overall scope of the present invention. [0064] The table tent panel 102 described herein is formed by generally stamping a foldable shape into a substrate or planar sheet 106, such as a metal sheet. An image 104 is placed on the substrate or planar sheet 106 by the methods described herein. The edge 126 of the sheet 106 is then folded into a non-planar shape. In the Figures, a non- rectangular shape is provided and folded or formed into the end product which is, in one or more examples of embodiments, a non-planar or three-dimensional table tent. Various cut-outs and/or fold lines 122 placed on the non-rectanguiar (or rectangular or polygonal or other) shape during the stamping or punching process allow it to be folded into a desired non-planar end product. That is, the planar sheet 106 is stamped or punched to form a desired shape for after image application formation into the final form of a table tent panel 102. Various geometries are contemplated and one of skill in the art will appreciate that a variety of cuts, recesses, apertures, and fold lines may be applied to allow the planar sheet 106 to be formed into a non-planar object after application of the image 104.

[0065] Unlike existing products, the disclosed table tent panel 102 can be made in a variety of shapes. Moreover, because of the sublimation process the table tent panel 102 may be formed to be smooth, having no raised or textured surfaces; or alternatively, may be textured as desired. Furthermore, unlike traditional art applications to a metal surface the metal panel 102 or substrate 106 can be bent to a degree in excess of 90 degrees without breaking the bond between the panel 102 and the applied image 104.

EXAMPLE 3

[0066] Referring to FIGS. 13-16, a further example of a panel 102 as described herein is shown and described. Specifically, FIGS. 13-14 illustrate a mailer or flyer. The mailer or flyer or panel 102 is formed of a single, monolithic component suitable for delivery through the mail without envelope, similar to a post card or flyer. Generally, the mailer panel 102 is label-less. In other words, no sticker or second component is added to the mailer panel 102 to form the finished product.

[0067] In one example, the mailer panel 102 is a metal mailer. An example of a suitable material is aluminum, although one of skill in the art will appreciate that numerous materials may be suitable for the purposes provided. Referring to FIG. 13, an elevation view of the mailer or panel 102 is shown having an image 104 thereon. FIG. 14 shows an elevation view' of the opposing side of the panel 102. In FIG. 15, on a second surface 112 of the planar sheet 106 namely the opposing surface, postal information or personally identifiable information 130 such as the requisite details needed for postal handling or mailing/shipment is provided, e.g., address, return address, as well as postage. FIGS. IS 16 show respective edges or side surfaces 114, 116 of the mailer panel 102 shown in FIGS. 13-14, illustrating the narrow width of the mailer thereby making it suitable for delivery through the mail .

[0068] As indicated, the image 104 may be directly applied to one side or surface 110 of the planar sheet 106 and/or to opposing sides 110, 112 of the planar sheet 106. In the example described herein, namely a mailer, postal information 130 is applied using the above-described sublimation process to at least one surface 110 or 112 of the mailer panel 102. Of course, postal information 130 may be applied to both surfaces without departing from the overall scope of the disclosure. It is contemplated that the opposing side or surface 110 of the mailer may have an image 104 or graphic, or other information which is desired to be conveyed, such as shown in FIGS. 13-14. However, the postal infomiation 130 and image 104 or graphic may be provided on the same side or surface. The opposing sides or surfaces 110, 112 of the planar sheet 106 may be sublimated at the same time or separately.

[0069] As previously discussed, the disclosed mailer or panel 102 can be made in a variety of shapes. In one example, the mailer may be generally rectangular. In another example, the mailer may have a unique shape such as illustrated in FIGS. 13-14. Moreover, because of the sublimation process the mailer may be made smooth, having no raised surfaces which could present problems for delivery through the mail.

Alternatively, the mailer or flier or panel could alternatively be formed with a textured surface. In one or more examples of embodiments, the mailer may also include a perforation or score line 122 or the like which allows the recipient to modify the mailer panel into its final form. In one or more examples of embodiments, the mailer is a multi- touch/muiti surface marketing mail media or direct mail media.

[0070] Uniquely, the mailer or panel 102 may be formed such that it can be sent through traditional mail with little or no increased cost. As the mailer panel 102 is so unlike a traditional paper mailing, it is eye catching to the consumer. Furthermore, the mailer may be formed of recyclable material (including materials which generate a monetary deposit, such as aluminum), providing an additional benefit to the consumer.

EXAMPLE 4

[0071] In one or more examples of embodiments, the panels 102 described herein may be perpetually reusable. For purposes of illustration one example is discussed, namely, an art panel, although the alternative panels discussed herein may be substituted in place thereof.

[0072] Due to the nature of traditional print methods, very few prints, if any, are truly sustainable due to either chemical or economic factors. Canvas, along with other materials traditionally used for prints, tend to have short life cycles and often end up as waste in landfills and in our oceans.

[0073] In the examples of embodiments described herein, unlike existing materials and prints, substrates 106 from previously formed prints and/or panels 102 can be repurposed. For example, a returned print or panel 102 may be broken down, properly disposing of the organic and inorganic materials used to create the image 104 currently on the substrate 106. The aluminum (or other material) substrate 106 may be brought back to level and fiat. The substrate’s surface 110 may be prepped and recoated with a coating 118 to accept sublimation dyes as described herein. And, a new image 104 may be applied.

[0074] More specifically, in one example of embodiments the following steps and/or procedures may be followed to accomplish the foregoing:

[0075] The returned panel 102 with image 104 may be baked or heated to a temperature of approximately 500 degrees Fahrenheit or greater to release the powder coat 118 from the aluminum substrate 106. Alternatively, the panel’s or substrate’s 106 printable surfaces 110, 112 may be abraded via chemical or mechanical actions resulting in the removal of the powder coat makeup previously bonded to the aluminum (or other) substrate 106.

[0076] Once the powder coat has been removed, the substrate 106 may be subjected to an ecologically sustainable washing process with wnter - e.g., recycled water.

[0077] With the substrate 106 now restored to its original state, it is ready for a new powder coat 118 application. A new image 104 to be transferred may also be provided; and the process of application of the image 104 described above is performed.

[0078] To facilitate one or more of the above-described steps to repurpose and reuse the panel(s), one or more additional steps may be employed. For example, when the original panel 102 is produced and packaged for a customer, the packaging and labeling may be designed and oriented in such a way that the customer is able to easily store and reuse it as a means and vessel for their art print’s ever evolving nature. When the panel 102 is first received by the customer, the information accompanying the panel 102 may also be carefully placed to convey the instructions regarding the return of the panel 102 in the future. When a customer is ready and able to return the panel 102 for reprinting and repurposing, the customer may reuse the original product packaging and a return label provided by at the time of original fulfillment. The customer may drop off the repackaged panel 102 to the nearest applicable parcel/package solution provider. The returned panel 102 may then be formally received into inventoried stock of reusable inventory, and subsequently reused.

[0079] As utilized herein, the terms “approximately,” “about,” “substantially”, and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the invention as recited in the appended claims.

[0080] It should be noted that references to relative positions (e.g., “top” and “bottom”) in this description are merely used to identify various elements as are oriented in the Figures. It should be recognized that the orientation of particular components may v ary greatly depending on the application in which they are used.

[0081] For the purpose of this disclosure, the term “coupled” means the joining of two members directly or indirectly to one another. Such joining may be stationary in nature or moveable in nature. Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another. Such joining may be permanent in nature or may be removable or releasable in nature.

[0082] It is also important to note that the construction and arrangement of the system, methods, and devices as shown in the various examples of embodiments is illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements show as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied (e.g. by variations in the number of engagement slots or size of the engagement slots or type of engagement). The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments.

Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the various examples of embodiments without departing from the spirit or scope of the present inventions.

[0083] While this invention has been described in conjunction with the examples of embodiments outlined above, various alternatives, modifications, variations, improvements and/or substantial equivalents, whether known or that are or may be presently foreseen, may become apparent to those having at least ordinary skill in the art. Accordingly, the examples of embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit or scope of the invention. Therefore, the invention is intended to embrace all known or earlier developed alternatives, modifications, variations, improvements and/or substantial equivalents.

[0084] The technical effects and technical problems in the specification are exemplary and are not limiting. It should be noted that the embodiments described in the specification may have other technical effects and can solve other technical problems.

Claims

IN THE CLAIMS: I. A panel comprising: a single, monolithic planar substrate; a coating on the substrate; and an image transferred thereon, wherein the panel is formable into a non-planar structure.

2. The panel of claim 1 , wherein the panel has a surface modification.

3. The panel of claim 2, wherein the surface modification is selected from the group consisting of laser removal, etching, engraving, perforation, and/or combinations thereof.

4. The panel of any of claims 1 to 3, wherein the image is selected from the group consisting of a graphic, artwork, information, and/or combinations thereof.

5. The panel of any of claims 1 to 4, wherein the image is provided on a first surface of the planar substrate.

6. The panel of any of claims 1 to 5, wherein the image extends the entire dimension of a surface of the planar substrate.

7. The panel of any of claims 1 to 6, wherein an image is provided on first and second opposing surfaces of the planar substrate.

8. The panel of any of claims 1 to 7, wherein the planar substrate is a metal sheet.

9. The panel of any of claims 1 to 8, wherein the metal sheet is aluminum.

10. The panel of any of claims 1 to 9, wherein the panel is an artwork.

11. The panel of any of claims 1 to 9, wherein the panel is a table tent.

12. A panel comprising: a monolithic metal sheet having an image sublimated thereon, wherein the image comprises postal information and a graphic or other information.

13. The panel of claim 12, configured for delivery through standard mail without an envelope.

14. The panel of claim 12, having a surface modification.

15. The panel of claim 14, wherein the surface modification is selected from the group consisting of laser removal, etching, engraving, perforation, and/or combinations thereof.

16. The panel of any of claims 12 to 15, wherein the graphic is provided on a first surface of the monolithic metal sheet.

17. The panel of any of claims 12 to 15, wherein the postal information is provided on a second surface of the monolithic metal sheet.

18. The panel of any of claims 12-17, wherein the monolithic metal sheet is a planar substrate having a coating suitable to accept the image.

19. The panel of any of claims 12-18, wherein the monolithic metal sheet is aluminum.

20. A method of forming a panel comprising: creating a planar sheet in a non-reetanguiar form having one or more fold lines; providing a coating on the planar sheet; and transferring an image to the planar sheet.

21. The method of claim 20, further comprising the step of folding the panel along the one or more fold lines to form a non-planar panel.